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Abstract
In turning process, the cutting tool is essential for shaping materials. The cutting tools with various perforated surfaces help to increase the cutting tool life. Also, advances in CNC machining technologies have enhanced the productivity of machining process. One of the best or futuristic approaches in modern manufacturing engineering is the use of FEM Simulation for the metal cutting process. FEM simulation helps in understanding the metal deformation process and also helps in the reduction of experiments. The simulation helps the researchers to predict the major influencing cutting variable values without carrying out any experiment which is time-consuming and expensive. This research presents the simulation study of the performance of micro-hole patterned Polycrystalline Diamond cutting insert in machining Titanium alloy (Ti-6Al-4V). Micro-holes are drilled using Electrical Discharge Wire Drilling machine on the rake face of Polycrystalline Diamond (PCD) cutting inserts. FEM analysis is carried out to evaluate the effect of perforations on the mechanical integrity of insert. The micro-hole patterned insert is modeled in PRO-E modeler and simulated using DEFORM-3D software. The effective stress, strain, and temperature distribution are analyzed and the results are compared with the normal insert.
Highlights
Titanium alloys are categorized as difficult to cut materials due to their low density, chemical reactivity at high temperatures and poor thermal conductivity
The excellent strength-to-weight ratio of Titanium alloy provides a decrease of aircraft parts weight and there is a decrease in fuel consumption and emissions
The increase in the cutting force is as a result of the strain hardening effect which modifies the inclination slightly and decreases between 175m/min to 200 m/min is owing to increase in cutting temperature resulting in the thermal tempering of the workpiece in the normal insert
Summary
Titanium alloys are categorized as difficult to cut materials due to their low density, chemical reactivity at high temperatures and poor thermal conductivity. These Titanium alloys have various applications in the field of aerospace, commercial, as well as military and medical applications. It is believed that cutting tool inserts with micro-holes or micro-dimples filled with lubricants are more significant in wear and friction fall at the chip-tool interface [2]. The cutting tool with different textures such as perpendicular, cross patterned and parallel geometries, which were used in the machining of aluminium alloy with various groove sizes ranging from microscale to nanoscale have been studied. Similar kinds of investigations were performed on different materials with different texture patterns by various authors and they concluded that for any given machining parameter the textured cutting tools had better results when compared with the normal insert or non-textured cutting tool[6,7,8,9]
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